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RAID configuration after drive failure

I recently ran the HP ADU as part of regular maintenance on our main server. The report came back that I had 2 drives failing on a RAID 5. I came in  the next morning and one of the drives had indeed failed overnight. The online spare had kicked in and had done it's job. I purchased 3 new drives and hot swapped one a day later . I ran the ADU again and was informed that the drive I had swapped was good and was being rewritten and that the online spare was active. The second "bad" drive was still functioning but was failing. I swapped that drive out as well. I am getting a failure message and the red led on the second drive I replaced. When I run HP Insight Diagnostics I am getting a report that this (new) drive is still bad. it is as if it is reporting on the drive I had just replaced and hasn't recognized the new drive. I am relatively inexperienced with RAID configurations and need an expert opinion. ADUReport.txt
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JPHopewell
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JPHopewell
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2 Solutions
 
DavidPresidentCommented:
Are you using the proper HP-branded disk drives? If not, please elaborate.
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JPHopewellAuthor Commented:
Yes, I am using the exact recommended HP replacement drives.
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DavidPresidentCommented:
No, let me be specific, ARE these the HP-branded disk drives, or are these the same drives, but w/o the HP firmware?
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JPHopewellAuthor Commented:
This is a HP ML350 G5 (SMART array E200i  with DG146BB976 HP 146-GB 10K 2.5" DP SAS HDD)
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JPHopewellAuthor Commented:
These are HP branded drives. I am unsure as to the firmware version on the new drives. The first drive I replaced seem to have worked fine and was incorporated in to the RAID so I will *cringe* assume that the firmware is correct.
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OriNetworksCommented:
Also just because it says HP doesnt mean its legit HP. Hopefully you purchased the replacement directly from HP or an authorized/reputable reseller. Also it might be good to verify that the firmware version is the same across all drives.
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JPHopewellAuthor Commented:
I purchased them from http://www.harddrivesdirect.com/contact_us.php?PHPSESSID=ejh6lu1hbjsdv6d2imvo9qht83 A cursory check did not return any known problems with the reseller.
May I ask how to check firmware versions on the drives?
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andyalderCommented:
Last Failure Reason                  Hot Removed (0x14)

Looks like you took the wrong drive out (disk 1)

Firmware is OK although not all are up to date.

It also says that the array (sas array A) has failed, is that the case? Is the system down?
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JPHopewellAuthor Commented:
No the system is still up and functioning. It appears that I may have indeed pulled the wrong drive although
I replaced the drive that was showing the red LED.
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JPHopewellAuthor Commented:
Currently It appears visually as if I have 4 good drives (slots 2-5) and a bad one (red LED) in slot 1 The diagnostic isn't finding the drive in the first slot and telling me that the drive in the second slot is going bad.
The drive in the 5th slot was my online spare.
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cmlbaeteCommented:
Just to concur with Andyalder my thoughts are the wrong drive was replaced.
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andyalderCommented:
Hmm, bit misleading in the ADU report then although it may be old.

If you search for "Physical Drive Error Log Entries" you'll see lists against each disk with entries such as this:
 
0x02       0x5a                0x00        0x22       0x00      0x00      0x00       0x00        0x3f000000 0x00000001     0x0000

A couple of them have rather long error lists but none of them have predictive failures or read / write errors so I'd suggest that except for missing drive 4 all is good.
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JPHopewellAuthor Commented:
So what should be my course of action? I have a drive in the first slot that is showing amber and is not being found, The drive next to it is going bad apparently with a 640004 error. The HDD in the first slot (showing amber) is one of the new drives I just purchased. Should I replace the new HDD in the first slot with the one I removed initially? Should I then replace the one going bad (slot2) with the new drive I pulled from the first slot?

See attached ADU report run just a few minutes ago. ADUReport.txt
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JPHopewellAuthor Commented:
Here is the Diagnosis log diagnosislog.html
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andyalderCommented:
I'd replace disk 1 since it's not found.
Disk 2 doesn't look that bad, only thing I can see is a few read errors that were corrected with retry.
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